What filler metals to use welding SA-203E to SA-240 304L

[TJHAK]

I have a base material of SA-203 E on a vessel that I need to add a section of SA-240 304L. I am trying to write a WPS for GTAW & SAW processes for making the girth welds. I have been told by my welding consumable vendors that ER309L wire will not suffice due to the 3.5Ni content of the SA-230 E. If not, what filler metals are acceptable with both base metals? Any help or advice will be greatly appreciated.

 

[metengr]

Use Inco A filler metal.

 

[metengr]

Inco Weld A

 

[TJHAK]

Thanks a bunch. Properties look exactly like what I am looking for.

 

[pradipgoswami]

Dear TJHAK,

What's the design temperature, thickness involved. Will SA 203GrE undergo PWHT. If so, one has to think carefully about the PWHT and it's implications on 304L. Recommended PWHT for SA 203 GrE is 1100deg F minm, which is good for 304L S.S.

Thanks

Pradip Goswami
Welding Engineer

http://www.opg.com.

 

[TJHAK]

Min design temp is -150degF. t=1 3/16".
PWHT @ 1100degF localized to affected areas. i.e. the SA-203 E sections welded. I do realize the heat will transfer to the 304L, but it should be plenty good for it.
I am not sure why this would affect filler metal classification though. If the filler metal is appropriate for both base materials, it's properties would allow it to be suggested to the same or greater stressors, correct?
PQR will require Charpy testing.

 

[pradipgoswami]

Dear TJ,

ASME Sec VIII,DIV-1, UCS-56 recommended PWHT cycle for SA203GrE(1 3/16"thk) would be typically @ 595-620 degC, around 1.30 hrs. UCS-66 allows, PWHT at lower temp, with larger soaking time. It's not clear from your email, if this is an external or internal weld , but there may be a scenario, the circ weld and the adjoining BM have to undergo PWHT at the above temperature.

Your best choice for such DMW's to use Inconel-82(GTAW/SAW) and 182(SMAW). The joint could be welded liks an usual pressure vessel C-Seam and locally PWHT or completely furnace PWHT.
Alternatively if possible 203 GrE weld egdes may be butterd with Inconel , PWHT then joined to 304L S.S using Inconel.

203 GrE is weldable with matching ferritic welding consumable,same applies to 304L S.S. However the DMW's would call for Inconel-82 /182 as typically common choice e.g. E-309L would not meet -150 deg F impact strength.

I was fortunate to handle this material SA 203GrE in India, for a number of large Ethylene projects,around 1984-85, soon after finishing my Masters studies.
Welding Nickel steel for such low temperature is quite challenging.We had successfully used Thyssen and Oerlikon welding products.

I have attached some literature for your reference.Feel free to drop a line, if you have queries.

Thanks

Pradip Goswami
Welding Engineer/Specialist

http://www.opg.com.